Forming and welding metal tubes and sheaths



Aug. 4', 1959 w. c. RUDD ETAL 2,898,440

FDRMING AND WELDING METAL TUBES AND sHEATHs Filed June '7, 1957 2 Sheets-Sheet -1 BY DA v/o C?. Os rEREE.

ML/MMJM ATURNEK.

AUS 4,` 1959 w. c. RUDD ETAL 2,898,440

- FORMING AND WELDING METAL TUBES AND SI-{EIAT-IS Filed June '7, 1957 2 Sheets-Sheet 2 A17-anvers..

A United States Patent() FORMING .This tinvention relates to methods and-.apparatus for formingand :for welding metal tubing and sheaths and f Amore particularly for meansl for shaping strips into tubul'arfform and for then*welding-.-a seam thereon-by .the luso of high frequency electrical resistance heating. Among other possible uses, the invention particular utilitygfror the continuous forming ofmetal sheathssurrounding cables contained therein and :for at the `same .time welding longitudinal seams lon such sheaths. Y

-With commonly used methods for forming metal tub'- ing, a continuous metal strip is-,advanced through ahltube mill and thereby formed to tubular shape vwith along- `tndinally extending gap.v vAs the tubular shapeis further advanced throughthe tube mill, .means are provided to apply pressure for 4closing the gap and at the same time forrforming aweldedseam.

One means by which the vwelding can be accomplished is disclosed in the co-pending application of Robert J.

' .stemmed Wallace o. Reda-semina 592,792, .ined

l'lt/Larch*V 1-4,` 1956, on which -Iatent Nol/33,910 was granted-on May l6,r 19.58,` and another of 'theirco-pending-applications, Serial No. 421,768, filed AprilfS, 195.4, lonwhich Patent No. 2,818,488 was granted on December .31,- 1957. These -patentsdisclose amethod-and appara- .tus for welding'together the .edges jdefining alongitudinal fgapfinv meta-l tubing ras'wthe tubing iis advanced longitu'dinally while-applying pressure theretoto closesaid .fgap at -a ,weld point. According to` said method, the heatingof -the gap edges -is effected by the 4use fof* electrodes connected toV an oscillatory :current/source and `applied respectively adjacent; to ,gap edges at 7points .positioned shortly in .advance of the vwelding',point,- ,thecurrent beingwof a frequency sufficiently .high so that the .lowest impedance, path .between the electrodespfollpws saidgap edges A`toand trorrrthe weld Apoing, In these `vpatents 4it was pinte'dgout `:thatfinsome cases, for ex- .'ample,- it the tbe diameter is relatively small, therewifll vatendency .forat .least .some part vof...the current .to .llow :circtnnferentially: around .thetubewinsteadf of along` )the edges .of .the \'lshaped..gap Yand .there .may .be .atendency :for the weld .point .to vary its positionawith loss .of

eiiiciency and irregularities lin the weld. further 55 pointed: out in said;V prior disclosures,` .thes'ediliicnlties kmay be minimized byincresing Vthe .impedance .of the current path from one'r of ythe contacts crcumfereritially ar the tubing to' tliotli, by mounting' within .the

ing aantast dieras, ,arianne farms ef magnefie means, Yiut/instl the resuittnaf the `in'creasedi'riipedanc'e 'saeed itlreiivfel'ding ftheitnbingl-nayfnherefoebe igeatyiinnesdfand their dalitymnd; uniformity-@of the weld may be improved.Y -fairness iwpendinsearnlieations fdisclesenfthatfthe magcareemeens-.prsferablx-comprises-for erariale?. reds of sintered magnetic oxide insulation material of known 2 .types which have a low loss factor and high volume rfesistivit-y, for example, Asuch `as the material marketed under'the'trade name Ferramic by' General Ceramics and Steatite Corporation. This material is ,a non-elc; trical conductor and has a Curie point inthe range of 200 to 300 F. However, since :the .heated tube dgs -at and near the weld point will come very close .to such material, particularly if the. tube diameter is small, si'- cient radiant heat may Vreach Lsuch core material either to injure same or to raise its temperature above the Curie point temperature so that lit ceases -to Vfunctin properly. l b Y As disclosed in said Patent No.2;833,910, it `found .that these problems may be satisfactorily overcome by surrounding the magnetic core material by suitable cotainer means, such asvcopper tubing, `v/hichfin turn is mounted within the advancing tubingbeingwelded and which container means also, preferably, s arranged to be continuously fluid cooled. However, in accordance with .the present invention, a solution to these .problems is accomplished in a different manner. u e

This invention provides a method and apparatus which during the weldingV operation provides a .core means which continuously movesin the tubing being welded and thus changes the surface portions of the core material which `are adjacent the .electrical contacts and the heated edges of the tubing. By thisv expedient `.no single Asurface portion ofk the coremeans absorbs excessive amounts of heat. vIn addition, no .single portion of the core .is continually exposed tothe heat at the edges of the tubing being actively welded.

More specically, the invention in one ofv its forms -involves continuously advancing along with the tubing, a continuous core member vcontained ftherein, such core member in one of itspreferred Aforms `comprising a steel cable which, if desired, may be left -within the welded tubing so that the product will comprise a welded tube or sheath formed for example of copper surrounding. a core in the form of a 'length ofvsteel cable or a cable comprising in part at least, a strand or strands of magrnetic material. According to another embodiment ofthe invention, as the tubingis advanced and the seam thereon is welded, a core `is mounted therein and arranged to 'be longitudinally reciprocated,y Aor reciprocatedk and also rotated if desired, so that no one portion of the core 1 will remain continuously in a position close tothe heated arcas on the `tubing being welded. l Y o The usual forms of tube mills adapted for shaping- -therstrips of tubular form and foradvancing same while `being welded are quite elaborate .and expensive since they involve .numerous rollers, Lstands and other equipment usually of a heavy Vand relatively complicated nature. According to another aspectof the present invention, instead of using a tube mill to shape and `advance the tubing, a much |less expensive anduless complicated lmeans is provided -in the form .of a `die member or aV plurality of succeeding die members, if necessary, Jthrough which -the metal strip is drawnand thereby 'shaped to tubular form just in advance of the means Vfor welding the longitudinal seam thereon. This aspectof .the invention is particularly well adapted for use when an extended length of electrical cable or the like is `to be enclosed vin ametal sheath.-

the welded seam by induction heating, it has notgenerallybeen possible practically :to `form a satisfactory welded seam on non-ferrous `metal sheaths such as 4copper or aluminum @or :alloys thereof, for various. rear Furthermore, it hasfnot beenpossible Atoyfora'n such. a rwelded sheathwhilej-a .cableisscontaincd therein or various `reasons, .eithuera by Iauch. induction-...heating o methods or by ordinary low frequecyaltenating current .by over-heating. The present invention overcomes these ditiiculties.

A further aspect of the present invention involves the provision of means for smoothing out or substantially leliminating any irregular surface portions along the welded seam, both internally and externally of the sheath as the same is being welded and notwithstanding the presence of a cable contained within the sheath.

Various further and more specific objects, features and advantages of the invention will appear from the description given below, taken in connection with the accompanying drawings, illustrating by way of example certain preferred forms of the invention.

In the drawings:

Fig. l is a schematic perspective view of one of the invention;

Fig. 2 is a longitudinal sectional view taken on a vertical plane through the form of the inventionv illustratedinFig. l; y

Fig. 3 is a schematic view, partly in section, of another embodiment of the invention;

Fig. 4 is a perspective view of another embodiment of the invention including die means for shaping metal Strips into the desired tubular form and surrounding, if desired, an advancing cable contained within the sheath as formed and welded, this embodiment also including means for smoothing out or eliminating irregularities along the welded seam both internally and externally ofthe tubing; j

Fig. 5 is a typical vertical transverse sectional View taken along line 5-5 of Fig. 4;

Fig. 6 is a vertical longitudinal sectional View taken along line 6-6 of Fig. 4; and

Fig. 7 is a perspective view, partially broken away, showing the means for smoothing out or eliminating irregularities along the welded seam.

Referring to Figs. l and 2, numeral 10 indicates the initial blank which is to be welded. This blank has been shaped into the approximate contour of the desired tube diameter having only the longitudinal V-shaped gap 11 separating the edges of the blank. The tube houses a multistrand lsteel cable generally designated by numeral 12. This cable may be comprised of a plurality of helically twisted wires such as are sometimes used to constitute or to form a core for communication cables. Each strand, or the cable as a whole, may in some cases be insulated.

The entire assembly of the tube, acting as a sheath, and the cable is advanced in a longitudinal direction indicated by the arrows by any convenient or conventional means, the welded sheath with the cable therein being finally wound into a coil as by a suitable power driven reel (not shown). The advancing means as shown may include power driven pressure-applying rollers 13 and 14. These rollers engage opposite sides of the tube near the weld point w to urge the opposite faces 15 and 16 within the gap 11 firmly against each other. These gap edges are advanced by the rollers past contacts 17 and 18. These contacts, or electrodes, are provided with connections to a suitable source of high-frequency current. The frequency should be of the order of about 100,000 cycles per second, or preferably more. For best results the frequency should be as high as 300,000 or 500,000 cycles per second, or more. The electrical contacts 17- and 18 are preferably duid-cooled as disclose in the above-mentioned patents. f

The contacts are located slidably to engage at or djacent the gap edges a suitable distancek in advance form of the weld point. Since the cable and tube blank advance simultaneously past the contacts, it is seen that no surface portion of the cable is exposed continuously to the heat of the welding process. The cable is thus well capable of withstanding without injury such heat as it receives in rapidly passing the weld point.

With the embodiment of the invention shown in Fig. l, the cable functions as a magnetic core impedor to increase the impedance of the circumferential current paths on the metal of the tubing. As a result, the current is closely concentrated where it is most desired; that is, along the edges of the V-shaped gap. This insures that efficient use is made of the welding current. By this expedient, the advantages of the methods disclosed in the above-mentioned co-pending applications are attained, while also permitting formation of a welded sheathed cable.

It will be noted that the sheath or tube blank w10 as shown, is slightly larger than the outside diameter of the cable. Thus, by the action of gravity, as the cable advances, it will rest on the lower inside surface of the tubing and out of contact with the current carrying portions along the tube gap, the spacing being indicated by numeral 19.

If in the finished product it is desired tol have the sheath closely embrace the cable, this may be accomplished by passing the assembly at some point subsequent to the weld point, through a suitable known form of swaging apparatus.

The embodiment illustrated above in connection with Figs. 1 and 2, illustrates moving the magnetic core material continuously past the heating area. By virtue of this expedient, no single portion of the core material is required to absorb an excessive amount of heat. Another means by which this may be accomplished is illustrated in Fig. 3.

In Fig. 3, the tube 21 may be the same as the tube 10 of Figs. 1 and 2, but does not carry its own impeder such as the cable 12. The means of moving or advancing the tube 21 may also be the same as that employed in connection with the previous embodiment. We have designated one of the rollers for providing the advancement of the tubing by numeral 22. The tube 21 advances longitudinally with a V-shaped gap therein the same as indicated at 11 in the first embodiment. The high frequency current is supplied by the electrodes, one of which is shown at 23, in the same manner as in Fig. 1. However, the impeder 24 in this embodiment may be the same general type as that disclosed in the patents aboveidentified, without however, the necessity of using cooling means. Means are provided in connection with this second embodiment longitudinally to oscillate or reciprocate the impeder along the heating region. This insures again that no surface portion of the impeder is continually subjected to the high temperature at the welding point. The reciprocations are of a frequency and amplitude to insure that a warm portion of the impeder is sufliciently removed often enough from the source of heat or heating area to allow it to cool suiciently before it is again subjected to high temperature.

Any convenient means may be used to provide such reciprocations of the impeder. Specifically illustrated in Fig. 3 is a luid motor, generally designated by numeral 25. The cylinder 26 contains a piston 27 and rod 28 which is oscillated back and forth by suitable known arrangements including a liuid pump (not shown) Ports 29 and 30 are provided to admit and exhaust the uid. The cylinder and assembly is mounted on suitable supporting meansas at 31. A connecting member 32 is provided to connect the piston rod 28 and the support 33 for the core 24, the core 24 being carried by the support33. f g.

Optional cooling means is providedat 34. l This cooling means is conventional and may "be used tospray "assenso .ya suitable cooling fluid onto theV core in the vicinity of the Welding zone, if found desirable. A g

The embodiment of the invention shown in Figs. l land.2- is ypartic'zularly `well adapted for 'the weldingof a sheath of metal such as copper about a steel cable, to secure a uniform weld along the sheath while at the same time avoiding any dangervof injury by heat to the cable. So far s lis known', no other method has heretofore beendevised which is suitable for electively carrying out such a purpose.

In the embodiment shown inrFigs. 4-7, parts corresponding to those `of Fig. l are identified by the same reference characters accompanied by prime marks. As shown in Fig. 4, a more or less hat strip of skelp as indicated at S is drawn through ya die member 40 to shape .it'as indicated into tubular form a's it advances to the welding means such as described in connection with Fig'. .1 and with a cable means as at 12', which may or may not be insulated, also continuously passing into the tubing as formed, preferably, although not necessarily, at the same rate of longitudinal movement.

The die 40 Vmay comprise, or its internal portions at least may preferably comprise, a plastic member suitably shaped tocause the strip entering same to be rapidly curled transversely into a tubular shape, preferably with a .gap 11', at oppositesides of which electrodes 17', 18' are applied. The diemernber may for example be formed of a phenol formaldehyde synthetic resin laminated, if desired, with material such Aas glass ber .sheets or paper. The die may be suitably mounted, adjustably if desired, by bracket means asat 41 and suitably clamped or held in position as by aset screw 42, whereby dies of various types, shapes and sizes maybe used interchangeably. By forming the .skelpinto tubular form in this way, the heavy expensive tube mills heretofore generally neces,- sary for the purpose are avoided, as are .also the diniculties of time-consuming readjustments of the tube mills to accommodate .tubing of different cross sections and sizes.

Thefdie tube Vforming arrangement above described is particularly Well adapted for shaping relatively thinwalled sheaths to tubular form, surrounding an advancing cable or the like, the latter aiding in preventing unintended displacement ofthe wall portions of the sheath as they are -being shaped into the desired tube.

To hold and maintain the gap in the tubing with uniform dimensions, a suitable, spreader means as at 45 is mounted to extend ydown into the gap shortly subsequent `to the die 40 and Vso that the edges of the tube ymetal'at the gap will be forced vby the die `firmly against the sides of the lower end .of such spreader. Thus the spreader in conjunction with the die serves to maintain a uniform gap, whereby the conditions of mutual inductance With respect to the high frequency current owing onthe gap edges as they approach the weld point will be maintained uniform and thus insure uniform heating and a uniform weld at thepoint w at moments very shortly subsequent toA the' original formation of the v tubinginthe die;

In vcase itis not 'desired' to have the high frequency current from the"electrodjes"17', 18 partially now along thegap edgesin advanc'eof the electrodes, then the lower ,portienofthe spreader at its sides may be formed with suitable cer'anii'cv insertsas vat 46, or otherwise provided with insulation-means Lto `prevent short-circuiting 4,of thejgapfedges at this region, f or example in a manner disclosed in the copending application of William C. Kalning, Robert J. Stanton and Wallace C. Rudd, Serial No. 558,060, tiled January 9, 1956.

In order to smooth out or eliminate any flash or irregularities along the welded seam which may tend to protrude inside the tubing, a metal member in the form of an elongated shoehorn as at 50 is mounted to extend along inside the tubing above the cable, one end bang *granny rapports fnfmigii are gaf-` 11' rv ing suitabiy attached for example by welding tothe spreader element 45. The raised inner end as at 50a of the members@ preferably extends forwardly the yWeld point w, itA being understood that `the sheath 1o as vfeinmedi'ri the die is madeof adiameter' siifnieiitly larger than the cable 12 to permit atleast soi'ne eletti"- ance for the member 50 in advance of the weld in order to press the-upper side of the uibiiigflo firmly down along the line yof the welded searn 51 and against the ar'ea 50a on the r'r'embe'r 50, a pressure roller as t 52 may beprovided. In opposition to the pressure provided by Athe roller '52, desired, a roller v5'3"-ir1tiy be mounted to engage the under'sur'faee of the 'tube 10at this region.

The -reinbe'r V50"is preferablyy foed of a suitable metal adapted to resist the temperatures occurring djacent the Weld point and to 'assistiti `cooling the 50 if desired, `the Spreader member 45 may be fiind with internal fluid eoolfirigcavitie's as in the ease vof 'the electrodes 1 7 and 1'8" asdis'elosed in Lthe above-nientioned patent. i y

At regions in advance of the weld point, it isrr oontemplated that the diameter of the sheath will still vbe sufficiently large so that the member 50 Will be spaced somewhat from the' metal of the tube gap edges, and thus avoid short=circiiiting the same.

In order to ,remove any yscarf or ash irregularities lfrom the external surfaces along the welded serny scraper' element as at SS may' be suitably mounted and provided with a sharpened edge as at 56 totengage under lpressure along the Welded s'ea'r'n shortly subsequentft Athe Weld point. Downward pressure by nieniber against the tubing may also he Aresisted by a roller urged against the unders'urface'v of the tubing, or if desired, the same roller as' indicated at' 53 in Fig. 7.

The advancing tubing containing the advancing cable may then pass on through two or more' pairs` of 'opposed driven pressure applying rollers as `indicated at 60, '61, l62 and' 63'. Themse the' tube may be advanced Vtl'ircirigh suitable known means as above explained, for bringing its diameter down s'o as to embrace the cble tothe extent desired.

Although certain particular eilodr'nentsy ofthe A-iiiinn'- tion 'are herein disclosed for purposesr ofjeitplantioii, further modifications thereof, after studyY of this speeiiication, will be apparent `to" those skilled in "the lartV 'to which `the invention pertains, Fori example, in accareance with some aspects of the invention, instead of ap lying the radio frequency ourrentfor resistance heating of the tube gap edges in the manner above described, the various methodsand apparatus for that purpose Amay be used as disclosed A'inuthe co=pending application of Wallace C. Rudd and ARoberth J. Stanton,- Serial N. '638,5-66, tiled February V6, l95f/ or other and apparatus suchyas' disclosed 'in U.S. Patent No. 2,774j8'57 to Wallace "CX Rudd and R'Ober'twLStanton, referentie to both of which is .hereby made. Reference should-be h'd to lthe appended claimsin determining. the scope ofthe invention.

What is claimed and desired' to be secured by Letters Patent is:

"1. 'Inapp'aratus for making metal tubing from a metal blank having been `previously .formed into a generally rtubular.configuration but having a longitudinal V-shaped gap between the edges of said blank, the' combination comprising: a pair' ef centacts mounted respectively te be engaged by the surfaces of the metal of said blank along opposite sides of said gap at a position shortly in advance of a weld point; a source of current of a frequency of the order of about 100,000 cycles per second or higher connected to said contacts; means embodying a continuing element of magnetic material positioned inside said blank and extending longitudinally thereof; and means for concurrently advancing said blank and said element with relation to said contacts and past said weld point while bringing the edges of said blank together at said weld point, successive portions of said element acting to increase the reactance of the paths of current flow between said contacts in directions around said blank and to thereby increase the current ow along the edges of said V-shaped gap to and from the weld point. Y l 2. Apparatus as claimed in claim l wherein said magnetic element is comprised in a multi-strand cable, about which the blank when Welded forms a sheath.

3. In a process for forming a metal tube from a metal blank, said blank having been previously formed into a generally tubular configuration but having a longitudinal V-shaped gap between the edges of said blank, the combination of steps comprising: positioning a continuing element of magnetic material inside said blank;

-conducting high frequency heating current to said blank at positions Aon the vsurface thereof at opposite sides of `said gap at locationsin advance of a weld point to cause such current to ow from said locations along on said edges respectively to and from the weld point; and continuously longitudinally advancing said blank and said element with relation to the locations of application of said current and past said weld point while bringing the edges of said blank together at saidweld point.

4. ln'a process for welding a longitudinal seam ina metal tube surrounding a steel cable, the combination of steps comprising: uniformly advancing the tubing longitudinally along with the cable as contained therein, while applying high frequency current to the metal of the tubing to heat same along the desired line of the welded seam at a region in advance of a Weld point, and the cable as it is advanced in the tubing being spaced from the line of the seam and acting as an impeder checking the flow of high frequency current in paths extending circumferentially around the tubing.

5. Apparatus for forming and applying a metal sheath to cables comprising: means for longitudinally advancing a strip of skelp together with the cable; die means having a synthetic resinous interior for shaping such advancing strip into a sheath of tubular form surrounding the cable but of substantially larger diameter than the cable and `having a longitudinal gap along which a welded seam is to be formed; a spreader in said gap following the die means and against which the gap edges leaving the die means slidably engage; means following said spreader for applying pressure to the sheath to close said gap at Aor adjacent a weld point; means for applying high frequency current to locations on opposite sides of the gap in advance of the weld point to ow from such locations to and from the weld point to heat the gap edges in advance of said weld point to welding temperature; and a device supported through said gap and extending out of contact with the heated edges of the gap and forwardly beyond the weld point within the sheath and between the interior walls thereof and the cable therein for engaging and smoothing out flash formations along the inside of the welded seam; means for applying pressure to' the outside of the welded seam for urging the seam areas against said device.

6. Apparatus for forming and applying a metal sheath to cables comprising: means for longitudinally advancing a strip of skelp together with the cable; means for shaping such strip into tubular form surrounding the cable, but of substantially larger diameter than the cable, and having a longitudinal gap along which a welded seam is `to be formed; means for applying pressure to the sheath to close said gap at or adjacent a weld point; means for applying radio frequency current to locations'on opposite sides of the gap inadvance of the weld point to flow from such locations to and from the weld point toheat the gap edges in advance of said weld point to welding temperature; a device supported through said gap and extending out of contact with the heated edges of the gap and forwardly beyond the weld point Within the sheath andy betweenthe interior walls thereof and the cable therein for engaging and smoothing out flash formations along the inside of the welded seam; and means for applying pressure to the outside of the welded seam for urging th seam areas against said device.

7. Apparatus for forming and applying a metal sheath to cables comprising: means for longitudinally advancing a strip of skelp together with the cable; die means having a synthetic resinous interior for shaping such advancing strip into a sheath of tubular form surroundingthe cable but of substantially larger diameter than the cable; means for applying pressure to the sheath to hold the edges of the strip in contact for welding at a weld point; means for applying high frequency current to locations on opposite sides of the gap in advance of the weld point to flow from such locations to and from the weld point to heat said edges in advance of said weld point to welding temperature; a device supported interiorly of the sheath and extending out of contact with the heated edges of the gap and forwardly beyond the weld point and between the interior walls of the sheath thereof and the cable therein for engaging and smoothing out flash formations along the inside of the welded seam; and means for applying pressure to the outside of the welded seam for urging the seam areas against said device.

8. In a method for forming a metal sheath with a longitudinally welded seam and enclosing a cable, the combination of steps which comprises: rapidly advancing metal tubing having a longitudinal gap therein and containing the cable in a position resting against the interior of the tubing opposite the gap and the tubing being of a diameter substantially larger than the cable, whereby the cable is spaced from the edges of said gap; applying pressure to close the gap substantially at the region of a weld point and conductively applying to points on opposite sides of the gap shortly in advance of the weld point heating current of a frequency of the order of about 100,000

cycles per second or higher to flow from said points to and from the weld point, thereby to heat the gap edges in advance of said weld point to welding temperature; applying means in the space between the cable and the interior of the welded seam shortly subsequent to the weld point to smooth out tiash formations on the seam; and thereafter passing the sheathed cable through means to reduce the diameter of the sheath to embrace the cable.

References Cited in the file of this patent UNITED STATES PATENTS 403,157 Thomson May 14, 1889 2,020,276 Crawford Mar. 5, 1935 2,029,044 Westlinning Ian. 28, 1936 2,146,430 Hazen Feb. 7, 1939 2,697,769 Carpenter Dec. 21, 1954 2,697,772 Kinghorn Dec. 21, 1954 2,794,108 Park May 28, 1957 FOREIGN PATENTS 1,095,095 France Dec. 15, 1954 

